Design of American Chopper Using Solid works

Designing of American Chopper

Objective: - Drafting and designing the American Chopper Bike using the SOLIDWORKS tool. 

Introduction:- 

The Design of the American chopper Bike involves creating the individual parts initially and assembling them together with proper connections and alignment. The individual parts involved in designing the Chopper Bike are as follows. 

• Chassis 
• Engine 
• Kickstand 
• Pedal 
• Transmission belt 
• Oil tank 
• Rear Wheel 
• Rear Fender 
• Chain 
• Gas Tank 
• Front Fork 
• Front Wheel 
• Front Fender 

Each part design has involved different options which will be explained in detail below and the assembly flow chart is as follows.

The Designing of this Chopper bike start from simple boss extrude and gradually increases the difficulty level for creating the parts

Transmission Belt:-

A transmission belt is used in the bike to transfer the mechanical energy obtained at the engine shaft to the transmission gears.

For designing this Belt we simply sketch the line diagram of the belt and extrude the sketch using the option available Boss Extrude option present in the features tab

Kick Stand:-

The kickstand is also called the side stand of the bike where it helps the bike to stand on the road

The kickstand design is made by using the Loft option which creates the line sketch into a hollow tube-like structure. The sketch is made on different planes to obtain the tube using the loft option. Here we also use the Dome option to create a dome-type end.

Pedal:-

A pedal is a type of footrest on the bike which is created simply by sketching the line diagram and applying Boss extrude. During this part creation we also linear pattern option which helps to create the similar objectives multiple times in a single line at a particular interval or fixed numbers.

Oil Tank:-

The purpose of an oil tank is to store the required fluid to help in combustion in the engine. The design of this tank involves a simple sketch and a Boss extrude option in this design we also use the combine option which helps to combine the two separate solid bodies to appear as a single body. The shell option present in the features tab helps to remove the solid material inside the part and creates the shell structure with respect to the given thickness value.

Chain:-

The design of the chain involves creating the block of plates which can be imported into the main part sketcher for ‘n’ a number of times and extruded in accordance with the requirement. For designing the chain, we use the curve-driven pattern where the repeating of the object follows the curved path of any type,

Front and Rear Fender:-

Fenders are designed by using a simple sketch that is converted to a 3D object by using the Revolve option available in the feature tab which helps to create a circular object for a required angle. All the sharp edges are made curved using the fillet option. A split option is used to split and remove the unwanted material from the final object.

Wheels:-

Wheels are designed using multiple options like Boss extrude, and Cut extrude which help top remove the sketched material, revolve, and circular pattern to create the Rim. Fillets are used to prepare the edges.

Chassis:-

The chassis is the base part of the Bike where every part is fixed. Chassis is designed with the help of simple sketches made using different planes and are extruded using the sweep option where we get the hollow tube-like structure individually and combine them to form a single solid object. As shown below

Front Fork:-

The design of the front fork involves a simple sketch of a line and it is formed into a solid object by using the options like revolve, boss, extrudes, Mirror, and combine.

Engine:-

The most complicated part of the bike design is the design of the engine. It involves various sketches on different planes that are converted to 3D objects using all the above options like Boss extrude, cut extrude, mirror, pattern, and sweep. Specially for creating the exhaust vents we use composite curve option which is used to create a curve where the two curve extrudes from 2 different planes meet and that joint forms as another curve to form a single curve .

Gas Tank:-

It is a hollow tank with a seat on it. The design of gas tanks like sheet metal design involves various options like the surface loft, surface sweep, surface extrude, and surface knit, which helps to develop a hallow tank as shown in the figure.

Assembly: -

All the above individual parts are assembled together with appropriate joint features to form the final output of the American chopper bike as shown below.

In solid works, we can add the material that appears to each individual part and get a realistic viewing effect using photoview360 where we can adjust the viewing direction using the camera option and place the model in a realistic environment and render the image as shown below.